gas type TOYOTA AVENSIS 2003 Service Manual PDF

F44819
F44820
±
PARKING BRAKE PARKING BRAKE CABLE ASSY NO.3
33±11
AVENSIS REPAIR MANUAL (RM1018E)
12. INSTALL PARKING BRAKE CABLE ASSY NO.3
(a) Connect the parking brake cable assy No.3 to the equaliz-
er.
(b) Install the parking brake cable assy No.3 with the 4 bolts. Torque: 5.0 N
m (55 kgf
cm, 48 in.
lbf)
(c) Install the fuel tank protector No.1 and 3 nuts (When re- placing parking brake cable assy No.2).
Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)
13. INSTALL FRONT FLOOR HEAT INSULATOR NO.2 (GASOLINE ENGINE TYPE) (See page 33±7)
14. INSTALL FRONT FLOOR HEAT INSULATOR NO.1 (GASOLINE ENGINE TYPE) (See page 33±7)
15. INSTALL EXHAUST PIPE ASSY FRONT 1ZZ±FE/3ZZ±FE ENGINE TYPE: See page 15±2
1AZ±FE/1AZ±FSE ENGINE TYPE: See page 15±7
16. CONNECT PARKING BRAKE CABLE ASSY NO.3
(a) Connect the parking brake cable assy No.3 to the backingplate.
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4105R±02
D30060
1ZZ±FE, 3ZZ±FE:
1AZ±FE, 1AZ±FSE, 1CD±FTV:
D30070
±
MANUAL TRANSMISSION/TRANSAXLE TRANSMISSION CONTROL CABLE ASSY (MTM)
41±7
AVENSIS REPAIR MANUAL (RM1018E)
TRANSMISSION CONTROL CABLE ASSY (MTM)
REPLACEMENT
HINT:
COMPONENTS: See page 41±10
1.REMOVE AIR CONDITIONER UNIT ASSY (See page 55±55)
HINT:
Refer to the instructions for removal of the instrument panel sub±ass\
y lower.
2. REMOVE EXHAUST PIPE ASSY
(a)1ZZ±FE, 3ZZ±FE Engine (See page 15±2)
(b)1AZ±FE, 1AZ±FSE Engine (See page 15±7)
(c)1CD±FTV Engine (See page 15±10)
3. REMOVE FRONT FLOOR HEAT INSULATOR NO.1 (GASOLINE ENGINE TYPE)
(a) Remove the 3 nuts and heat insulator No.1.
4. REMOVE TRANSMISSION CONTROL CABLE ASSY
(a) Remove the 2 clips, separate the 2 cables from the trans-axle.
(b) Remove the 2 clips, separate the 2 cables from the brack- et.
(c) Remove the 2 nuts, separate the control cable assy.
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D26894
Serrate Part
D30070
D30060
1ZZ±FE, 3ZZ±FE:
1AZ±FE, 1AZ±FSE, 1CD±FTV:
±
MANUAL TRANSMISSION/TRANSAXLE TRANSMISSION CONTROL CABLE ASSY (MTM)
41±9
AVENSIS REPAIR MANUAL (RM1018E)
(d) Connect the end of the select cable to the shift lever assy
and install the clip.
NOTICE:

The serrate part of the select cable point should face
upward when the select cable point is connected.

The clip should be inserted to the direction as shown
in the illustration.
(e) Connect the end of the shift cable to the shift lever assy.
(f) Connect the control cable assy with the 2 nuts. Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
(g) Connect the 2 cable ends, install the 2 clips.
(h) Install the 2 clips to the control cable bracket.
6. INSTALL FRONT FLOOR HEAT INSULATOR NO.1 (GASOLINE ENGINE TYPE)
(a) Install the heat insulator No.1 with the 3 nuts. Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)
7. INSTALL EXHAUST PIPE ASSY
(a)1ZZ±FE, 3ZZ±FE Engine (See page 15±2)
(b)1AZ±FE, 1AZ±FSE Engine (See page 15±7)
(c)1CD±FTV Engine (See page 15±10)
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4202V±03
D30477
LHD Steering Position Type:
RHD Steering PositionType:Clutch Master Cylinder To Flexible Hose Tube
Clutch Reservoir Tube
Clutch Master Cylinder
Push Rod Clevis w/ Hole Pin

Gasket
Clip
Clutch Master Cylinder Assy Clutch Master Cylinder To Flexible Hose Tube
Clutch Reservoir Tube Clutch Master Cylinder
Push Rod Clevis w/ Hole Pin
Clutch Master Cylinder Assy Clip

Gasket
N
m (kgf
cm, ft
lbf) : Specified torque
Non±reusable part


12 (120, 9)
12 (120, 9)
15 (155, 11)
15 (155, 11)
MP grease
42±12
±
CLUTCH CLUTCH MASTER CYLINDER ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH MASTER CYLINDER ASSY (MTM)
COMPONENTS
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D30782
RHD Steering Position Type:
LHD Steering Position Type:
MP Grease
D30069
SST(s)
D30068
Blue Mark
42±14
±
CLUTCH CLUTCH MASTER CYLINDER ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
7. REMOVE CLUTCH MASTER CYLINDER ASSY
(a) Remove the 2 nuts clutch master cylinder assy and gasket.
8. INSTALL CLUTCH MASTER CYLINDER ASSY
(a) Install the clutch master cylinder assy and gasket with the 2 nuts. Torque: 12 N
m (120 kgf
cm, 9 ft
lbf)
9. INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W/HOLE PIN
(a) Apply MP grease to the contact surface of the hole pin and clevis bush.
(b) Connect the clevis to the clutch pedal assy with the hole pin.
HINT:

RHD steering position type:
Install the hole pin from the right side of the vehicle.

LHD steering position type:
Install the hole pin from the left side of the vehicle.
(c) Install the clip to the hole pin.
10. CONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE
(a) Using SST(s), connect the flexible hose tube. SST 09023±00100
Torque: 15 N
m (155 kgf
cm, 11 ft
lbf)
11. CONNECT CLUTCH RESERVOIR TUBE
(a) Connect the clutch reservoir tube with the clip to the clutch master cylinder assy.
NOTICE:
Connect the clutch reservoir tube so as not be twisted.
12.INSTALL BRAKE BOOSTER ASSY (LHD STEERING POSITION TYPE) (See page 32±19)
13. INSTALL BRAKE MASTER CYLINDER SUB±ASSY (LHD STEERING POSITION TYPE) (See page 32±13)
14.BLEED BRAKE LINE (LHD STEERING POSITION TYPE) (See page 32±4)
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±
HEATER & AIR CONDITIONER COMBUSTION TYPE POWER HEATER SYSTEM
55±17
AVENSIS REPAIR MANUAL (RM1018E)
5. DIAGNOSTIC TROUBLE CODE CHART
If a malfunction code is displayed during the DTC check, check the circuit\
listed for the code in the table below
and proceed to the appropriate page.
DTC No.Description of faultComment / Remedy
000No malfunction±
010
011Overvoltage shutoff
Undervoltage shutoffVoltage between 1 and 5 at connector A > 16 V
Voltage between 1 and 5 at connector A < 10.2 V
(Voltage values must be present > 20 seconds)
Check battery, regulator and electrical leads.
012Overheating
Check temperature at temperature or overheating sensor >
125
C
Check water circuit.
014Possible overheating detected
(Hardware threshold value)
Difference of measured values at temperature sensor > 15
C
(min. 70
C water temperature and metering pump in opera-
tion);
Check temperature sensor and overheating sensor, replace if
necessary.
017Overheating detected
(Hardware threshold value)
Temperature at temperature or overheating sensor > 130
C,
emergency OFF if DTC No. 012 or 014s not applicable;
Check water circuit, temperature sensor and overheating sen-
sor, replace if necessary.
020Glow plug breakCheck glow plug, replace if necessary.
021Glow plug output overloadCheck glow plug, replace if necessary.
030Combustion air blower motor
EMF outside perm. range.Blower impeller or burner motor fammed (frozen solid, dirty,
etc.)
Remedy jam, replace burner motor if necessary.
031Combustion air blower motor breakCheck the lead to combustion air motor (burner motor) for
continuity, replace if necessary.
032Combustion air blower motor short±circuit
Check combustion air blower motor (burner motor), replace if
necessary.
Check supply lead (chafed, etc.).
047Metering pump short±circuitCheck the supply lead to metering pump for short±circuit,
check metering pump, replace if necessary.
048Metering pump breakCheck the supply lead to metering pump for continuity, remedy
break, replace metering pump if necessary.
051Cold blow time exceeded
At start, if flame sensor above 70
C, > 240 sec.;
Check exhaust gas combustion air supply, check flame sen-
sor, replace if necessary.
052Safety time exceeded
When all perm. start attempts used up;
Check the fuel delivery and fuel supply.
Check exhaust gas and combustion air ducts.
054Flame cutout, High settingCheck the fuel delivery and fuel supply.
Check exhaust gas combustion air ducts.
056Flame cutout, LOW setting
Check exhaust gas combustion air ducts.
If combustion OK
Check the flame sensor, replace if neces-
sary.
060Temperature control sensor break
Check connecting leads.
Resistance value between 2 and 10 connector B > 2 M
(if
break)
061Temperature control sensor short±circuit
Check connecting leads.
Resistance value between 2 and 10 at connector B < 2 M
(If
short± circuit)
064Flame sensor break
Check connecting leads.
Resistance value between 7 and 14 at connector B > 3,040

(If break)
065Flame sensor short±circuit
Check connecting leads.
Resistance value between 7 and 14 at connector B > 780
(If
short±circuit)
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550ZI±01
I35437
Connector ºBº
Wire harness side:
Connector ºAº
I36091
Connector ºBº
From back side:
Connector ºAº
55±22
±
HEATER & AIR CONDITIONER HOT GAS TYPE POWER HEATER SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
HOT GAS TYPE POWER HEATER SYSTEM
ON±VEHICLE INSPECTION
1. INSPECT AIR CONDITIONING CONTROL ASSY
(a) Disconnect the connector from air conditioning control assy and inspect the connec\
tor on wire harness side, as shown in the table.
Symbols (Terminal No.)Wiring ColorConditionSTD Voltage (V)
SOL+ (B17) ±
GND (B40)R ± W±BStart engine
Compressor: OperatePulse generation
MGV (B14) ±
GND (B40) (*1)R±Y ± W±BStart engine
Compressor: OperatePulse generation
HOT GAS IN (B22) ± GND (B40) (*1)R±Y ± W±BIG SW: ON
Hot Gas SW: ONBattery positive voltage
If circuit is not as specified, try replacing the air conditioning control\
assy with a new one. If the circuit is not
as specified, inspect the circuits connected to the other parts.
(b) Connect the connector to air conditioning control assy and inspect wire harness side connector from the back side, as shown in the table.
Symbols (Terminal No.)ConditionSpecified condition
HI (A4) ± GND (A1)Ignition switch ON
Turn blower dial: OFF
HINo continuity
Continuity
M2 (A5) ± GND (A1)Ignition switch ON
Turn blower dial: OFF
M2No continuity
Continuity
M1 (A6) ± GND (A1)Ignition switch ON
Turn blower dial: OFF
M1No continuity
Continuity
GND (A1) ± Body groundIgnition switch ON
Turn blower dial: OFF
LONo continuity
Continuity
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550ZJ±01
I36136
I32396
EIN
IG
±
HEATER & AIR CONDITIONER HOT GAS TYPE POWER HEATER SYSTEM
55±23
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. INSPECT W/RECEIVER CONDENSER ASSY
(a) Apply voltage between terminals and check that the re-
frigerant passages switch.
2. INSPECT HETER SWITCH ASSY
(a) Check that the continuity to the follwing terminals. Standard:
Heater switch conditionConnecting terminalsStandard value
ONIG ± INContinuity
OFFIG ± INNo continuity
ONIG ± EContinuity
OFFIG ± ENo continuity
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I35337
I35336
I35339
I35340
55±94
±
HEATER & AIR CONDITIONER W/RECEIVER CONDENSER ASSY
AVENSIS REPAIR MANUAL (RM1018E)
5. REMOVE DISCHARGE TUBE SUB±ASSY (W/ HOT GAS HEATER)
(a) Remove the 2 bolts and disconnect the discharge tube
sub±assy from the w/ receiver condenser assy.
(b) Remove 2 O±rings from the discharge tube sub±assy.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape
to prevent moisture and foreign matters from entering.
6. REMOVE LIQUID TUBE SUB±ASSY B (RHD(1CD±FTV) STEERING POSITION TYPE)
(a) Remove the bolt and disconnect the liquid tube sub±assy B from w/ receiver condenser assy.
(b) Remove the O±ring from the liquid tube sub±assy B.
NOTICE:
Seal the opening of the disconnected parts using vinyl tape
to prevent moisture and foreign matters from entering.
7. REMOVE HOOD LOCK ASSY
(a) Remove the 3 bolts and the hood lock assy.
8.REMOVE HIGH PITCHED HORN ASSY (See page 69±5)
9.REMOVE LOW PITCHED HORN ASSY (See page 69±4) 10. REMOVE HOOD LOCK SUPPORT BRACE
(a) Remove the 5 bolts and the hood lock support brace.
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I35344
I35343
I35342
I35336
±
HEATER & AIR CONDITIONER W/RECEIVER CONDENSER ASSY
55±97
AVENSIS REPAIR MANUAL (RM1018E)
20. I N S TA L L M A G N E T VA LV E A S S Y ( W / H O T G A S
HEATER)
(a) Install the magnet valve assy with the 4 bolts.
Torque: 3.4 N
m (35 kgf
cm, 30 in.
lbf)
21. INSTALL REFRIGERANT FILTER (W/ HOT GAS HEATER)
(a) Install the refrigerant filter to the discharge tube.
22. INSTALL DISCHARGE TUBE (W/ HOT GAS HEATER)
(a) Install the discharge tube with the 2 bolts. Torque: 5.4 N
m (55 kgf
cm, 47 in.
lbf)
23. INSTALL LIQUID TUBE SUB±ASSY B (RHD(1CD±FTV) STEERING POSITION TYPE)
(a) Remove the attached vinyl tape from the tube and the connecting part of the w/ receiver condenser assy.
(b) Sufficiently apply compressor oil to a new O±ring and the fitting surface of the pipe joint.
Compressor oil: ND±OIL 8 or equivalent
(c) Install the O±ring on the liquid tube sub±assy B.
(d) Install the liquid tube sub±assy B on the w/ receiver con- denser assy with the bolt.
Torque: 5.4 N
m (55 kgf
cm, 47 in.
lbf)
24. INSTALL DISCHARGE TUBE SUB±ASSY (W/ HOT GAS HEATER)
(a) Remove the attached vinyl tape from the tube and the connecting part of the w/ receiver condenser assy.
(b) Sufficiently apply compressor oil to a new 2 O±rings and
the fitting surface of the pipe joint.
Compressor oil: ND±OIL 8 or equivalent
(c) Install the O±ring on the discharge tube sub±assy.
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